( BARABANKI MANUFACTURING DIVISION )

Summer Training Project

Report
HSEF Department
“ A case study on manufacturing process of Polyester fiber involving
various Hazardou Chemicals & Fire Protection facilities at RIL(BMD)”

Submitted by:
Kritarth Srivastav
B.Tech (Fire & Safety Engineering)
Final Year (Batch 2014-18)
University Of Petroleum & Energy Studies
Dehradun.
 ACKNOWLEDGEMENT

With the will to attain more practical knowledge in chemical manufacturing

industries, I have taken efforts to correlate the theoretical knowledge to practical.
My Project on a case study on manufacturing process of Polyester fiber involving
hazardous chemicals & Fire Protection facilities at RIL (BMD) exposed me to the
vast field of industrial safety and gave me the immense knowledge about various
safety aspects and related techniques but this would not have been possible
without the help and guidance of Department of Health, Safety & Environment at
Reliance Industries Limited (Barabanki Manufacturing Division).

I am immensely grateful to my guide Mr.Ejaj Ahmed and Mr. Sudhanshu Ji

Sahuliyar (Safety) who has guided me to complete the project and also arranged
the industrial visit at the premisis.

I also indebted to my guide for his generous help in viewing the whole project and
providing constructive guidance and encouragement during the term of this
project.

I would also like to express gratitude towards other Departments of RIL (BMD) for
their kind cooperation & encouragement which helped me in completion of the
project.
 DECLARATION

We hereby declare that the work being presented for Summer Internship project
entitled “A case study on manufacturing process of Polyester fiber involving
hazardous chemicals & Fire Protection facilities at RIL (BMD)” is an authentic
record of work that has been carried out at Reliance Industries (Barabanki
Manufacturing Division) under the guidance of Mr.Ejaj Ahmed & Mr.Shudhanshu
ji Sahuliyar HSE Department.

The data mentioned in this project was obtained during the genuine work done
and was collected by us. Any other data or information in this report, if collected
or borrowed from outside agency has been duly acknowledged.
.

Mr. Ejaj Ahmed Mr. Shudhanshu ji Sahuliyar

Mentor Mentor
(Fire Department) (Head-HSEF Department)

Kritarth Srivastav
B.Tech (Fire & Safety Engineering)
Final Year
Batch: 2014-18
Roll no: R260214016
UPES-Dehradun-248007
 EXECUTIVE SUMMARY

The Production or Synthesis of Polyester Fiber involves the Management of Fire

and Safety at Reliance Industries (Barabanki Manufacturing division) as it deals
with various hazardous chemicals such as Purified Terephthalic Acid, Mono
Ethylene Glycol, Triethylene Glycol which may lead to Fire and explosions if
proper care and safety of these chemicals is not taken into account.

Management of Fire and Safety at RIL-BMD employees the methodology which

deals with the step by step study of Hazard Identification and estimation of the
Risks involved in factories and provides the technique to reduce those risks.

A Program known as ReSOP(Safety Observation Program) is also launched by the

company to ensure continous safety and motivation among the workers.

This Project contains sequential information of the basic process of Polyester

Fiber Synthesis and Fire Protection Systems installed at RIL-BMD.The Hazardous
chemicals which are involved in the formation of Polyester fiber are also taken
into study with major concern on Health & Environment.
 COMPANY PROFILE

Reliance Industries Limited is an Indian conglomerate holding company

headquartered in Mumbai, Maharashtra, India. Reliance owns businesses
across India engaged in energy, petrochemicals, textiles, natural resources,
retail, and telecommunications.

Reliance is the most profitable company in India, the largest publicly traded
company in India by market capitalization, and the second largest company in
India as measured by revenue after the government-controlled Indian Oil
Corporation.

Reliance Industries Limited (Barabanki Manufacturing Division) is a

polyester fiber manufacturing unit and is one of the largest producers of dope
dyed black and colored fiber in India via recycle route (Through PET Bottles
Flakes) and via virgin route (with the use of petrochemicl called PTA i.e
Purified Terephthalic Acid, which comes from other units of Reliance
Industries limited such as Dahej Unit, Patalganga unit )
 (Safety Prayer)

न न ||
न न न ||
न ….................||
न औ ब |
|
न |
न न न |
न …................||
न |
न औ न न नन |
न |
न न न |
न ….....................||
 ABBREVIATIONS
 OISD Oil Industry Safety Directorate
 NFPA National Fire Protection Association
 TAC Tariff Advisory Committee
 PPE Personal Protective Equipment
 SCBA Self Contained Breathing Apparatus
 MSDS Material Safety Data Sheet
 DCP Dry chemical powder
 MAP Mono Ammonium Phosphate
 MCP Manual call point
 AIT Auto ignition temperature
 FP Flash Point/Fire Point
 LFL Lower Flammability Limit
 UFL Upper Flammability Limit
 HSEF Health, Safety , Environment & Fire
 BLEVE Boiling Liquid Expanding Vapour Explosion
 VCE Vapour Cloud Explosion
 LPM Litre per minute
 GPM Gallon per minute
 DG Diesel Generator
 FO Furnace Oil
 HSD High Speed Diesel
 LDO Light Diesel Oil
 CP Continous Polymerization
 PET Polyethylene Terepthlate
 PTA Purified Terepthalic Acid
 MEG Monoethylene Glycol
 TEG Triethylene Glycol
 DOW Phenyl Ether-Biphenyl Mixture
 PSF Polyester Staple Fiber
 ETP Effluent Treatment Plant
 AR-AFFF Alcohol resistant aqueous film forming foam
 TERMINILOGY RELATED TO FIRE & SAFETY

 Incident: A situation arising out from a happening in the plant which may
cause injury to individual(s) and/or damage to work environment.This may
be a minor or serious incident.
 Emergency: An emergency could be defined as any situation which
presents a threat to safety of persons,property and/or the environment.It
may require outside help also.
 On site emergency: A situation arising out of FIRE/EXPLOSION/SPILLAGE in
Plant.
 Combustion: It is a self sustained exothermic chemical reaction (Oxidation,
not necessarily or most of the time) of a fuel which gives out heat, light and
smoke & other gaseous product.
 Fire: It is a unplanned combustion or can be defined as a force, a hazard
and a potential annihilator(destroyer) which can cause harm to life,
property or environment and which can at no stage be ignored or be
treated with anything but at the highest priority.
 Fire load: The caloric value of the whole contents, contained in a space
including the facings of the walls, partitions and ceilings.
 Fire load density: It is the product of caloric value and mass of the fuel
divided by total floor area.
 Flash point: The minimum temperature at which a liquid fuel gives
combustible vapours in sucha way that they produce a momentary flash
when an ignition source is introduced in its vicinity
 Fire point: The minimum temperature at which the liquid fuels gives off
sufficient amount /concentration of vapours so that they can get ignited or
can be ignited.
 Auto Ignition Temperature: The lowest temperature at which the
combustible substance ignite without any spark or flame (or external
ignition source)
 Flammability Range: The range of concentration of fuel vapours to
air/oxygen in which the particular fuel is combustible is called flammability
range.
 Incipient Stage: When the fire has just started and is confined to the
material which is first ignited. Product of combustion are invisible at this
stage
 Smouldering Stage: When the smoke appears and the rate of burn
becomes noticeable.
 Flame Stage : If not checked, the fire develops to flamming stage where the
flame appears and the fire grows rapidly.
 Heat Stage: At the heat stage, the ambient temperature and the
temperature of all items in the area become very high.
 Starvation: Removal of fuel (A fire will go out if deprived of its fuel supply)
 Smothering and Blanketing: Removal or Limitation of Oxygen (A fire can be
extinguished by removing or limiting its oxygen supply)
 Cooling: Removal of heat (Water is most commonly used for cooling a
fire It has the greatest heat absorbing properties of all liquids. If the rate of
heat produced by the fire is lower than the rate of heat absorbed, the fire
will go out)
 Flashover: Whenever there is a smoke thein it creates a radiation shield
which increases the temperature of the compartment & nearby
combustible substance get auto ignited due to increase in temperature
which is known as flashover.
 Smoke Gas Explosion: In a confinement when layer of smoke increases
,then the amount or volume of oxygen decreases & when the space is
exposed to outer environment it get blast due to availability of oxygen,this
is called smoke gas explosion or Backdraft.
 BLEVE: It is a sudden loss of containment of pressure vessel containing
superheated liquid or pressure liquified gas (PLG). It is a physical explosion
 VCE: When a large amount of flammable vapourizing liquid or gas is rapidly
released, a vapour cloud forms and disperses with surrounding air. The
release can occur from storage tank, transport vessel, or pipeline. If this
 cloud is ignited before the cloud is diluted below its lower flammability
limit(LFL) a VCE or flash fire will occur.
 Fire Extinguisher : It is a first aid fire fighting equipment device which can
be used to suppress the small intensity fire or fires in initial stages. A fire
extinguisher are installed at the strategic locations (locations where it can
be easily accessible in case of fire)
 Fire Hydrant System : A fire hydrant system is a network of pipes
connected to a source of water supply and is provided with outlets for
tapping water (under pressure) in order to deliver water in desired
discharge patterns of stream,spray or fog through attached hose & nozzle
with intent to effectively extinguish the fire and protect endangered assets
or people (both occupants and fire fighters)
 Fire Monitors: Fire Monitors are the permanent mounted water nozzle,
often elevated to prevent obstructions so that the monitor can direct a high
pressure stream of water over a wide area. They are provided in emergency
areas & inaccessible areas where it is impractical to lay hose lines.
 Fire Pump: A fire pump is an integral component of a total fire protection
sytem. A pump that is a provider of liquid flow and pressure dedicated to
fire protection & fire services-NFPA 20:2013
A pump that is capable of discharge rate of atleast 250 GPM (US) at a net
pressure of 150 PSI (g) is called fire pump.
 Primary Pump: It is an electrically driven pump used to supply bulk amount
of water
 Secondary Pump: It is a diesel engine driven pump used to supply bulk
amount of water
 Jockey Pump: It is solely dedicated to maintain appropriate pressure in the
fire water network.
 Fire door: : A fire door is a door with a fire-resistance rating used as part of
a passive fire protection system to reduce the spread
of fire and smoke between separate compartments of a structure and to
enable safe egress from a building or structure.
 Bund Wall: It is a constructed retaining wall around storage "where
potentially polluting substances are handled, processed or stored, for the
purposes of containing any unintended escape of material from that area
until such time as remedial action can be taken.
 Smoke detector: A smoke detector is a device that senses smoke, typically
as an indicator of fire.
 Safety Shower: A safety shower would be installed in a work place where
large amounts of corrosive acids or bases are used. If a chemical spill occurs
involving parts of the body, the worker can go under the safety shower and
wash off the chemicals before severe skin burns occur.
 Incineration: It is a burning of waste in a closed system, under carefully
controlled condition such as kiln or furnace.
 Incinerator: an apparatus for burning waste material, especially industrial
waste, at high temperatures until it is reduced to ash.
 Blowdown: It is the emergency or a planned depressuring of a process
equipment. This is a critical process safety operation. It may be necessary in
the event of fire, leak, pipeine rupture or other hazardous situation as well
as planned shutdown. Devices such as control valves, relief valves, rupture
disks transfer the potentially dangerous contents of a process equipment to
a safe lower pressure loacation or to a flare system for controlled
combustion.
 Flame Arrestor: It is a device which allows gas to pass through it but stops a
flame in order to prevent a larger fire or explosion.
 ReSOP
(SAFETY OBSERVATION PROGRAM)

Safety Observation Program is a unique program launched by the company to

ensure continual safety of the plant and workers and to enhance the overall
productivity. It is the responsibility of every officers of different department of
a plant to carry out ReSOP time to time.

ReSOP is a six step process and is done weekly or monthly.

The Steps to carry out ReSOP are:

1).Observe, decide how to approach the employee, stop the unsafe act(safely)
2).Comment on unsafe act/behaviour
3).Discuss any unsafe/at risk behaviour observed
 Discuss consequences(possible injury) of the unsafe act or behaviour
 Encouarge the employee to discuss safer ways to do the job
4).Get agreement to work safely
5).Invite the employee to discuss other safey issues in the workplace
6).Thanks the employees.

SAFETY STATISTICS (RIL-BMD)

 Last LTA (date) 07.09.2011
 No Fire incident since April 2006
 No Spillage Incidents since: Oct 2005
 TABLE OF CONTENT
S.No. Topics Page no.
1 Introduction
 Background 14-16
 Problem Areas
2 About Polyester
 Characteristics of Polyester
 Polyester Staple Fibre (Saturated 17-19
Polyester)
 Uses of Polyester Staple Fibre
3 Polymerization Reaction 19
4 Polyester Process Flow
 Process Description 20-23
 Process Flow Block Diagram for PSF &
TOW
5 On site Emergencies at RIL-BMD 23-25
 Level of Emergencies
6 Risk prone areas at RIL-BMD 25
7 Properties of Hazardous Chemicals used at
RIL-BMD 25-30
8 Objective & Purpose of Fire Protection
Facilities at RIL-BMD
 Fixed Fire Protection System 30-42
a) Fire water reservoir
b) Hazard Consideration for RIL-BMD
c) Fire Water Requirement at RIL-BMD
d) Foam Calculation
e) Fire water Pump
f) Hydrant

9 Hydrant Flow Testing 43-44

10 Fire Monitors 44-45
11 Passive Fire Protection System
 Fire Doors 46
 Dyke Walls
12 Fire Detection Systems 46
13 Portable Fire Protection System
 ABC Type Fire Extinguisher 47-54
 CO2 Type Fire Extinguisher
 AR-AFFF Used in Fixed & Portable
Monitors
14 Conclusion 55
15 References 56
 INTRODUCTION

At Reliance Industries Limited (Barabanki Manufacturing Divison) ,the

concern for safety could be said to focus on two main area:

 PROCESS SAFETY

 LABOUR or PERSONNNEL SAFETY

Over the last 20-30 years, in Petroleum Refineries and in chemical process
industries, there have been several significant incidents. These incidents have
fueled the development of many of the regulations and prevention activities
that apply today and that serve to minimize the impact of the hazards
typically associated with Reliance Industries Limited(Barabanki
Manufacturing Division)

BACKGROUND

 Reliance Industries Limited (Barabanki Manufacturing Division) is

located in remote area and it stores large quantity of FLAMMABLE
MATERIALS. Such as PTA, MEG, TEG, HSD etc

 Such conditions therefore, make it necessary for the introduction of

inbuilt FIRE PROTECTION FACILITIES

PROBLEM AREAS

At Reliance Industries Limited (BMD), the concern for safety could be said to
focus on two main areas: process safety and labour or personnnel safety.
These two areas are very different from each other, but both are important.
  Process Safety involves the development and implementation of action
which is concentrated on preventing or minimizing (ALARP: As low as
Reasonably Predictable) the effects of loss of containment of
flammable, toxic or reactive chemicals.
 Labour or Personnel safety focus on the prevention or mitigation
(effort to reduce the loss of life) of hazards that can result in individual
injuries or exposures; a much less catastrophic (which causes great
damage) problem, but a no less important one.

 Through both approaches to the safety problem, RIL (BMD)

attempts to prevent or minimize the impact of ACCIDENTS.
 Accidents are considered to be the unintentional events that
result in undesirable consequences when different
people/persons repeat similar kind of mistake.
 Accident occur in nearly every aspects of our lives.
 Because in factories, there is extensively heavy manual work;
there is large, heavy equipment; there are toxic, flammable and
reactive chemicals; and there are high temperatures and
pressures in many processes, it is no surprise that accidents occur
here. Over the last 20-30 years, in chemical processes industries &
Petroleum Refineries ,there have been several significant
accidents such as
 Bhopal Gas Tragedy (2ND December 1984)
 Piper Alpha– Oil Rig Fire Disaster (July 1988)
 IOCL Jaipur Disaster (29 October 2009)

Such incidents have fueled the development of many of the regulations and
preventions activities that are applied today and that is served to minimize
the impact of the hazards typically associated with factories
The RIL (BMD) Plant releases a different chemicals into the atmosphere and a
notable odour.

Aside from the air pollution impacts there are also wastewater concerns, risks
of individual accidents such as fire and explosion, and noise health effects due
to industrial noise.

ABOUT POLYESTER

Polyester is a term often defined as “long-chain linear polymers chemically

composed of at least 85% by weight of an ester and a dihydric alcohol and a
terephthalic acid”.. Reaction of alcohol with carboxylic acid results in the
formation of esters.

Polyester also refers to the various polymers in which the backbones are
formed by the “esterification condensation of polyfunctional alcohols and
acids”.
 CHARACTERISTICS OF POLYESTER

 Polyester fabrics and fibers are extremely strong.

 Polyester is very durable: resistant to most chemicals, stretching and
shrinking, wrinkle resistant, mildew and abrasion resistant.
 Polyester is hydrophobic in nature and quick drying. It can be used for
insulation by manufacturing hollow fibers.
 Polyester retains its shape and hence is good for making outdoor
clothing for harsh climates.
 It is easily washed and dried.

POLYESTER STAPLE FIBER

Saturated Polyester

Polyester staple fiber(PSF) is a kind of polyester fiber made directly from PTA
& MEG or PET Chips or from recycled PET bottles flakes. PSF made from PTA
& MEG or PET Chips is known as Virgin PSF & PSF made from Recycled PET
flakes is called Recycled PSF.

100 % Virgin PSF is usually costly than recycled PSF & is also more hygienic

USES OF PSF

PSF is mainly used for fibre fillings in pillows and Sofa. It is also used widely in
spinning to make polyester spun yarn which is then weaved into fabrics.

It is used to make ropes in industries. PET bottles are today one of the most
popular uses of polyester.
PSF Produced at Reliance Industries Limited (Barabanki Manufacturing
Division) is known by the name “RECRON FIBER” and the one which is
produced using PET Bottles are called “RECRON GREEN FIBERS”

POLYMERIZATION REACTION
(Esterification)
CATALYST USED : ANTIMONY TRIOXIDE (Sb2O3)
In order to remove transperancy a chemical called Titanium dioxide (TiO2)
Is used in polymerization Reaction.

POLYESTER PROCESS FLOW

 PTA Charging
 PTA Conveying
 PTA Esterification
 Polymerization
 Spinning
 Annealing & Crimping
 Drying & Relaxing
 PSF Cutting
 PSF Baling
 Bale Conveying

PROCESS DESCRIPTION
1).Using forklift 1 MT PTA bags are shifted and carried out and is unloaded to
individual hoppers using hoist (This is called PTA CHARGING).

2).PTA is conveyed to PTA Storage Silo by Nitrogen blowing(This is called

PTA CONVEYING, although this method is stopped at RIL-BMD to save cost
and energy consumption, At present these 1MT Bags of PTA are directly
loaded with the use of lifts)

3).PTA slurry in EG is prepared in slurry mix tank and is continously

transferred to slurry feed tank for injection in heat exchanger
(ESTERIFICATION)

4).Polymerization Reaction is performed under high temperature & high

pressure.
5).Polymer is extruded through spinnerets and quenched (rapid cooling) to
form spun filament. (SPINNING)

6).Spun tow is drawn to impart spinnable textile properties (DRAWING)

7).Drawn fiber is annealed(heat treatment) and crimped in annealer and

crimper (ANNEALING & CRIMPING)

8).Crimped Tow is dried to remove excess moisture (DRYING & RELAXING)

9).Processed Tow is cut in a fiber cutter (CUTTING)

10).Fiber cut in cutter is baled in a baling press (BALING)

11).After this the bale is conveyed and packed & printed.

PROCESS FLOW BLOCK DIAGRAM FOR PSF &TOW

Refinery

Naphtha PX PTA
(RIL-BMD)
Oil & Gas from cracking PLANT -1
(Mother Earth)
Ethylene EO MEG

PSF TOW

FABRIC

The area under the brackets are under the scope of Reliance Industries
Limited (Barabanki Manufacturing Division)
PLANT-1 (PTA ROUTE)

Continous
Polymerizati • Capacity
on • 90 TPD
(CP)

• Capacity
Spinning • 100
TPD

Drawline,Cutter • Capacity
& Baler • 100 TPD

PSF TOW

PLANT 2 (PET RECYCLE ROUTE)

PET Flakes
Used PET Bottles
Crushed to Washline Washed
flakes Flakes

PSF
RIL-BMD

PLANT 2

TOW
PET FLAKES FROM WASHLINE

Melt extrusion & PSF

Drying & Conveying Drawline,Cutter,Baler
Spinning
Capacity: 30 TPD Capacity: 60 TPD
Capacity: 30 TPD
TOW

Emergencies which can arise at RIL-BMD

Types of emegency that can arise at Reliance lndustries limited

(Barabanki Manufacturing Division) are as follows:

1). Fire-hazards from high level of thermal radiations snd smoke e.g. tank fires
containing flammable liquid hydrocarbon, degraded polymers, degraded PET
flakes, PTA, PET Bottles etc.

2) Explosion from pressurised vessels/lines

3) Spillage and/or leakage of flammable/toxic material such as dowtherm, EG,
HSD, TEG, RFO, LDO, Lub Oil & HCL.
4). Fire in vegetation growth, grass, rice husk, coal fires.

Causes of Emergency

Fire:
Fire in flammable liquids, storage tanks, pipelines, PET flakes, PTA storage area etc
Fire in transformers, electrical cables and electrical installations
Fire in thermal insulation, false ceilings etc.
Fire in CP, Spining/PET spinning, Auxilaries ares : TEG bath,CPF. etc

Leakage:
Leakage of flammable liquids (HSD, LDO, DOWTHERM, EG, Lub Oil etc)
Leakage of flammable gases (LPG, Hydrogen etc)
Leakage of flammable vapours(Dowtherm, EG, TEG etc)
Leakage of other chemicals(HCL etc)

Explosion

Explosion due to mixture of PTA dust & air

Explosion in pressure vessel (Boilers)
Explosion in storage tanks
Explosion in battery room due to spark or any ignition

Others

Corrosion
Equipments Failure
Electrical short circuit
Natural calamities
Departmental significant aspects/hazard
Likely illness.

Level-1 Emergency

This Emergency is perceived to be a kind of situation arising out due to an

incident, which is confined to a smaller area and does not pose an immediate
threat to life, environment and properties and can be handled with resources
available within the premises

Level-2 Emergency

This emergency is perceived to be a kind of situation arising out due to an

incident which poses threat to human lives, environment and property, having
potential to affect large areas within the premises and beyond the control with
the internal resources and require mobilisation of additional resources from
outside (neighbouring industries and mutual aid etc.)

List of areas in the factory where an environment disaster may occur

Finished Product Godown

PTA Storage Area
EG, TEG & DOW Storage Area
Fuel Oil & Diesel Storage Area
DOW Vaporisor
Steam Boiler
Hypox & Rypox Shed
DG Shed
HCL Storage tank
PET Flakes Storage
Continous Polymerization & Spinning
Incinerator
Rice Husk Boiler
Rice Husk storage yard
Coal Storage Yard

IMPORTANT PROPERTIES OF SOME HAZARDOUS CHEMICALS USED AT RIL-BMD

Purified Terephathalic Acid (PTA)

Chemical Name: Benzene-1,4-Dicarboxylic Acid

OSHA Status: Hazardous

Hazard Identification: Powdered material may form explosive dust-air mixture
Hazard Rating: Health-1, Flammability-1, Reactivity-0
Physical & Chemical Properties
Physical form: Solid (Powder)
Color: White
Odour: Odourless
Flash Point: 271o C
Autoignition
Temperature: 496 o C

Unusual Fire & Explosion Hazard: Powdered material may form explosive dust-air
mixture.
Fire-Fighting Measures: Water spray, Dry Chemical
Fire-Fighting Procedures: Wear self contained breathing apparatus and protective
clothing. Use water spray to keep fire-exposed containers cool.
Accidental Release: sweep up & place in a container for chemical waste
First-aid Measures: Inhalation: If symptomatic, move to fresh air, get medical
attention if symtoms persist
Eyes: Any material that contacts the eye should be washed out immediately with
water. Get medical attention if symptom persist
Ingestion: Seek medical advice.

Mono-Ethylene Glycol (MEG)

Chemical Family: Glycols
NFPA Rating(Scale 0-4): Health-2, Fire-1, Reactivity-0
Change in Appearance: Hygroscopic (Ability of substance to attract and hold
water molecules from surrounding environment)
Color: Colorless
Physical Form: Liquid
Odour: Odourless
Major Health Hazard: Respiratory Tract Irritation, Skin Irritation, Eye Irritation,
Central Nervous System irritation.
Flash Point: 111 0 C
Lower Flammability Limit: 3.2 %
Upper Flammability Limit: 15.3 %
Autoignition: 398 o C
Fire & Explosion Hazard: Slightly Fire Hazard
Extinguishing Media: Alcohol Resistant foam, CO2, Regular dry chemical.
Large Fires: Use Alcohol Resistant foam or flood with fine spray.
Fire Fighting: Move container from fire area if it can be done without risk.
Do not scatter spilled material with high pressure water stream. Dike for later
disposal. Use extinguishing agaents appropriate for surounding fire. Avoid
inhalation of material or combustion product.
Accidental Release measures: Stop leak if possible without personal risk.
Small Spills: Absorb with sand or other non combustible material. Collect spilled
material in appropriate container for disposal. Keep unnecessary people away.
Isolate hazard area and deny entry.Notify local Emergency Planning Committee &
State Emergency Response commission for greater release.
First –Aid Measures:
Inhalation: If adverse effect occur, remove to uncontaminated area. Give artificial
respiration if not breathing. Get immediate medical attention
Skin Contact: Wash skin with soap & water for at least 15 minutes while removing
contaminated clothing and shoes. Get medical attention if needed. Thoroughly
clean & dry contaminated clothing and shoes before reuse.
Eye Contact: Flush eyes with plenty of water for atleast 15 minutes. Then get
immediate mediacl attention.
Ingestion: If vomiting occurs, keep head lower than hips to help prevent
aspiration. If person is unconscious, turn head to side. Get medical attention
immediately.
Antidote: ethanol, oral; Calcium gluconate/glucose, intravenous : 4-methyl
pyrazole.

DOWTHERM
Chemical Name: Phenyl-Ether-Biphenyl Mixture

Physical & Chemical Properties

Physical State: Liquid
Appearance: Straw-Colored
Odour: Aromatic Odour
Flash Point: 123 o C
NFPA Rating: Health-2, Flammability-1, Reactivity:0
Fire Fighting Measures: During a fire irritating & highly toxic gases may be
generated by thermal decomposition or combustion. Use water spray to keep fire
exposed container cool, wear SCBA. Vapours may be heavier than air, they can
spread along the ground and collect in low or confined areas. Container may
explode when heated.
Extinguishing Media : Use agent most appropriate to extinguish fire, use water
spray, dry chemical, carbon dioxide or appropriate foam.

Accidental Release Measure:

General Info: Use proper PPE as indicated
Spills/leaks: Absorb spill with inert material (e.g. vermiculite, sand) then place in
suitable container. Avoid run off into storm sewers and ditches which lead to
water ways. Clean up spills immediately. Remove all sources of ignition, Provide
ventilation.
Exposure control & Personal Protection
Engineering Controls: Facilities storing or utilizing this material should be
equipped with an eye wash facility and a safety shower. Use adequate ventilation
to keep airborne concentration low
Exposure Limits:
Chemical Name Concentration

According to NIOSH
1 PPM (TWA)
DOWTHERM 7 mg/m3 (TWA)
(Phenyl –Ether-Biphenyl Mixture) 10 PPM IDLH

OSHA final PELs

1 PPM TWA
7 mg/m3 TWA

Potential Health Effect: Causes Eye,Skin Irriation

Ingestion: Digestive &Respiratory tract irritation

First Aid Measures:

Eyes: Flush eyes with plenty of water for at least 15 minutes, occassionally lifting
the upper and lower eyelids. Get medical aid.
Skin: Get medical aid. Flush skin with plenty of soap & water for atleast 15
minutes.
While removing contaminated Clothing & shoes wash clothing before reuse.
Ingestion: Never give anything by mouth to an unconscious person. Get medical
aid. Do not induce vomiting. If conscious and alert rinse mouth and drink 2-4
cupfuls of milk or water.
Inhalation: Remove from exposure to fresh air immediately. If not breathing, give
artificial respiration. If breathing is difficult, give oxygen. Get medical aid.

Purpose & Objective of Fire-Protection facilities at reliance Industries

Limited(Barabanki Manufacturing Division)

PURPOSE:

The Purpose of Fire-Protection facilities at Reliance Industries Limited(BMD)

is to protect/prevent the fire hazards arising due to use of various hazardous
chemicals for the synthesis of polyester fiber and to protect the life of
workers, property & damage to the environment

OBJECTIVE:

 To minimize the risk and consequences of an accidental event

 To minimize the potential for hazardous occurrences
 To ensure safe working environment for personal
 To provide sufficient safety devices to detect, isolate and minimize
uncontrolled release of flammable and toxic liquids and gases
 To provide appropriate fire protection system to rapidly bring under
control and extinguish any forseeable fire which could develop during
normal operations
 To minimize the potential for pollution of the environment from
accidential spills, venting or flaring of hazardous material
 Fire Protection Facilities at Reliance Industries Limited
(Barabanki Manufacturing Division)
The fire protection systems provided at RIL-BMD are broadly classified into
two categories:

FIRE PROTECTION

ACTIVE FIRE PROTECTION PASSIVE FIRE COMMUNICATION

SYSTEM PROTECTION SYSTEM SYSTEM

FIXED FIRE PORTABLE FIRE FIRE DOORS

PROTECTION PROTECTION
DYKE WALLS
SYSTEM SYSTEM
TELEPHONE

PUBLIC ADDRESS
FIRE WATER SYSTEM
RESERVOIR FIRE SIRENS
FIRE
FIRE WATER FIRE ALARM
EXTINGUISHER
PUMP SYSTEM
WATER & SAND (MCP & SMOKE
FIRE WATER
BUCKET DETECTORS)
NETWORK,
HYDRANT
&MONITORS
FIXED FIRE PROTECTION SYSTEM
Fire-water Reservoir

The Fire water storage reservoir at Reliance Industries limited (Barabanki

Manufacturing Division) is designed to provide continous 2 hrs water supply at
the rate of 150 % of the maximum fire water demand.

i.e Total water requirement at RIL-BMD is approx. 487.4 m3/hr

therefore 150 % of 487.4 = 730 m3/hr (approx.)

There is a common water reservoir having capacity of 1492.45 m3 for process and
fire water of which 753.45 m3 is reserved for fire water. Inflow to the reservoir is
by mean of two no. of bore wells located(1) in southwest side of water treatment
plant and (2) south of hyundai DG cooling tower. The capacity of the base well
pumps (2 no.s) is 136 m3/hr and both the pumps are having emergency power
connection from diesel generating sets. The reservoir is kept full by running bore
well water pumps.

HAZARD CONSIDERATION FOR RELIANCE INDUSTRIES LIMITED (BMD)

The Reliance Industries Limited (BMD) consist of the Processing Plant:

 CP (Continuous Polymerization)
 Spinning
 Fiber Line
 Utility (Compressor House, DG ,ETP, Boilers)

The plant is classified as ordinary hazards as per the TAC FP Manual Table-1

NATURE OF RISK CAPACITY OF STATIC STORAGE EXCLUSIVELY

RESERVED FOR HYDRANT SERVICE.

1. Light Hazard Not less than 01 hour’s aggregate pumping

capacity with a minimum of 1,35,000 litre.
 2. Ordinary Hazard Not less than 2 hour’s aggregate pumping
capacity.

3. High Hazard (A) Not less than 3 hour’s aggregate

pumping capacity

4. High Hazard (B) Not less than 4 hour's aggregate pumping

capacity

Therefore the static storage water should be reserved for hydrant service in such
a way that it can supply water for not less than 2 hrs of the rated pump capacity.

Fire water requirement/demand at RIL-BMD

Since RIL-BMD comes in ordinary hazard occupancy and as per the table for the
no. of hydrants (100+) the following pumping capacity is available for RIL-BMD

Pumps Capacity
Pump 1 273 m3/hr
Pump 2 97 m3/hr
Pump 3(Diesel Engines) 97 m3/hr
Pump 4(Diesel Engines) 273 m3/hr
Aggregate 740 m3/hr
Fire water storage demand:

According to Fire Protection Manul (Part 1) of TAC, Water requirement for hose
stream protection for storage tank where the largest tank in a dyke has a
diameter:

Diameter of Tank Capacity

Upto 10 m 1150 LPM
More than 10 m & upto 20 m 2250 LPM

As there is no tapping from hydrant service for waterspray or foam.

For diameter upto 10 m the water requirement for hose stream protection shall
be of 1150 LPM.

Similarly, water requirement for foam protection would be same as 1150 LPM.

Calculations

The largest storage tank at RIL-BMD is of 8.9 m diameter

For 2 hydrants: (1150 * 2)

= 138 m3/hr (For water spray)
Water Demand for foam spray : 69 m3/hr
Therefore 138+69 =207 m3/hr (This is the total water demand for tank
protection)
According to TAC Guidelines

Nature of Risk No. of hydrants Pump Capacity Delivery

( m3/hr ) Pressure at
pump discharge
at rated
capacity
(kg/cm2)
Ordinary Hazard i) Not exceeding 20 137 7

ii) Exceeding 100 273 7

iii) for every 273+ 273 8.8

additional 125
hydrants

Minimum running pressure shall be 3.5 kg/cm2. At this point the hydrant system
shall be so designed that the rate of flow of water does not exceed 3 m/sec
anywhere in the system.

Calculation

For ordinary hazard having 100 + hydrants points, the pumping capacity would be
273 m3/hr.
As per TAC guidelines the pumping capacity for 2 hrs would be of 546 m3/hr.
Total water available at RIL-BMD = 753.45 m3/hr.

As per the Factories Act 1948

In every factory, adequate provision of water supply for fire fighting shall be made
& water requirement shall be calculated as:

Water requirement =( A+B+C+D)/20

Where
A= Total area in square meter of all the floors and galleries in all the buildings of
the factory
B= Total area in square meter of all the floors and galleries including open spaces
in which combustion material are handled or stored.
C= Total area in square meter of all floors over 15 metres above ground level
D= Total area in sqaure meter of all floors of the buildings other than those of fire
resistant construction.

Calculation
A= 12274 m2
B= 28631 m2
C= 1209 m2
D= 2375 m2
= 44489 /20 =2224.45* 100= 222445 litres for 100 minutes
Water demand in m3 for 100 minutes= 222.445 m3 for 100 minutes
For 60 minutes it will be (222.445*60)/1000= 133.467 m3/hr.
Thus,
For tank protection, water demand=207 m3/hr
For protection of other area including all dykes,water demand= 133.467 m3/hr
Total Fire Water Requirement=349.467 m3/hr

Water calculation for tank farm and other areas after fire hydrant revamping

1 hydrant stream =36 m3/hr

1 water monitor from onr side= 159 m3/hr
1 foam monitor from one side= 159 m3/hr

Thus water requirement with reference to TAC, OISD & Factories Act 1948
Total = 36+159+159+133.467= 487.467 m3/hr
Or say Fire water demand = 500 m3/hr

Water available at RIL-BMD is 753 m3/hr

Largest pump capacity is 273 m3/hr
Water required for 2hrs for ordinary hazard occupancy is 273+273=546 m3/hr
Foam Calculation (NFPA 11 & OISD )

Foam branch is of 225 LPM

= 225*0.03(Foam Concentrate) * 65= 438.75 litres
Consider 10 minutes for low hazard having large capacity fire monitors
Foam monitors=2650(foam monitor capacity)*0.03*10= 795 litre or 800 litres

Foam used at RIL-BMD is AR-AFFF.

There are two foam station :1) MEG tank farm 2) RFO tank farm

Fire water pump

Fire water pump are designed to deliver fire water at range of 150 % of its rated
capacity/FWD.Note: Application of the pump at the capacities less than 90% of
the rated capacity is not recommended.
The details of main hydrant pump is at Reliance Industries limited(BMD) is given
below :

Description Pump 1 Pump 2 Pump 3 Jockey Pump 4

(Electrical) (Electrical) (Diesel) Pump (Diesel
Engine)
Type Centrifugal Centrifugal Centrfugal Centrifug Centrifugal
al
Capacity 4560 LPM 1620 LPM 1620 LPM 180 LPM 4550 LPM
Discharge
Pressure 7.2 kg/cm2 8.2 kg/cm2 8.2 kg/cm2 7 kg/cm2 7 kg/cm2

The system pressure is maintained at 7kg using the jockey pump.

Fire water network

The fire water network is hydraulically designed to provide a minimum

residual pressure of 3.5 kg/cm2 at the most hydraulically remote point when
the maximum fire water as per the demand is being discharged midway of the
fire water network with maximum velocity of 3 m/s.

The adequate no. of isolation valves are provided on the fire water network
ring mains at about 300 meters and at grid junctions for isolation of required
portion for maintenance/repair.

Hydrants:
The hydrants are placed around the periphery of the plant and for the storage
tanks outside the dyke walls.
Fire hydrant stand post is of 80 mm NB, and one meter above grade level,
fabricated with one outlets fitted with a 63 mm hydrant valve. The wet riser is
having single outlet hydrant valve provided at each staircase landing of plant
building.

Hydrant Outlet/Post
Types of Nozzles avaialble at RIL-BMD

Fog Nozzle
Foam branch nozzle
Revolving Branches
TFT (Task flow triple purpose)
Navy Cut
Diffusor
HYDRANT FLOW TESTING (NFPA 291)

Calculations

Hydrant No: 51
Date of Testing: 29/07/2017
Residual Pressure= 2.5 Bar= 36.25 psi
Static Pressure= 4.2 Bar= 60.91 psi
Pitot Pressure= 20 psi
Nozzle Diameter= 2.5 inch
Coefficient of discharge= 0.90

(Three General types of hydrant outlets & their discharge coefficients)

Formula

where:
c = coefficient of discharge (see Figure 4.7.1)
d = diameter of the outlet in inches
p = pitot pressure (velocity head) in psi

Calculations
a) For Individual hydrant flow
Q= 29.84 X 0.90 X (2.5)2 X (20)0.5
= 750 GPM

b) For system flow

Qf =Qr ( Ps-20/Ps- Pr )0.54

= 750 x (60.92-20/60.92-36.26)0.54
= 750 x 1.314
= 985.5 GPM (System Flow)

On coverting GPM to m/s we get 3.4 m/s. (which is in the range)

Fire Monitors

Fire monitors are the permanent mounted water nozzle, often elevated to
prevent obstructions so that monitor can direct a high pressure stream of
water over a wide area. They are provided in emergency areas & inaccessible
areas where it is impractical to lay hose lines.
They are installed at locations such as diesel tank farms, RFO tanks , MEG ,
TEG storage areas at Reliance Industries Limited (Barabanki Manufacturing
Division)

There are total 5 Fire monitors installed in the plant out of which 3 fixed
monitors are installed for Diesel & RFO tank farm, 1 fixed monitor & 1
movable monitor for DOW, TEG & MEG storage areas.
These monitors can be used to direct water from hydrant system on to the
required area from a distance.
These monitors can give a horizontal throw of about 55 m & vertical 30 m

Monitor Movement

Water monitors can be rotated by:

1). Horizontally: 0 O to 30 O
2). Vertically : 45 O to 800
Passive Fire Protection

Fire doors : The purpose of fire door is to reduce the spread of fire or smoke
between compartments and to enable safe egress from a building or structure.

The Fire doors are installed at various locations in the plant including the
hazardous building of the plant i.e CP (Continous Polymerization) Building,
Finished Product Godown etc.
Dyke walls: These walls are provided at the boundaries of the tank farm at
RIL-BMD in order to prevent spillage and withstand fire for certain duration
of time.

Fire detection system

Fire dectection system is designed to

 Provide visual and audible alarms in the respective control centre
 Alert personnel to danger
 Initiate preventive/shutdown action at an early stage in order to
mitigate the consequences of fire and/ or chemical release
 Initiate protection system (if required)
 Initiate starting of fire pumps as an effect of system actuation.

Fire detection system at RIL-BMD consist of various sensors like smoke

detectors and Manual call points (MCP).

Smoke detectors (Optical) are installed in unmanned PCC rooms , MCC rooms
and invertor rooms. Aspiration type smoke detectors are installed in
warehouse & PTA Godowns.

MCPs are installed at various strategic locations in the plant depending upon
the requirement of that area.
Gas detector sytem is installed in UPS Battery room at 12 m CP and hydrogen
generation room in compressor house
 Portable-Fire Protection System.

The portable fire fighting equipment is designed tocontrol/extinguish fires at

their incipient stage.They are also called first aid fire fighting equipment.

Considering the nature of fire hazards and the criticality of the equipment in
the complex, the following basis is considered for providing the portable fire
fighting equipment.
1). For hydrocarbon liquids & gas fires in the plant, Dry chemical powder type
fire extinguishers are provided.

2). For electrical/electronic panels and equipments ,the process control

rooms, plant interface buildings, sub stations & non process building in plant
Carbon dioxide & DCP type fire extinguishers are provided.

The extinguishers are distributed in the process areas in such a way that the
travel distance from any point in the plant is not exceeding 15 metres and
placed at conspicuous loacation with ease of accessibility to lower the risk.

Use of fire extinguisher to be used for various class of fires

Class Of Fire Description Extinguisher to

be used
Class A Fires involving ordinary combustible materials
like paper, wood, textiles, PTA, PET Flakes,PSF, Water,Soda-
Rice Husk, Coal etc. Acid Type

Class B Fires in flammable liquids like MEG,TEG,DOW

RFO,HSD, PETROL etc Foam Type

Class C Fire involving gases (under pressure) e.g LPG,

Hydrogen, Acetylene DCP Type, CO2
Type
 Class D Fires involving metals like magnesium,sodium etc DCP Type,
CO2 type
Class E Fires in Electrical equipment DCP Type,
CO2 Type

Use of Fire Extinguishers for various chemical fires at RIL-BMD

Name of Chemical Class of fire Substance to Extinguish

PTA, PSF, PET Flakes, Rice A Soda Acid, Water
Husk, Coal
Mono-Ethylene Glycol B Foam, C02, DCP
(MEG)
RFO B Foam, C02, DCP, Steam
Blanketing
HSD, LDO, Lub Oil B Foam, C02, DCP, Steam
Blanketing
DOWTHERM B Foam, C02, DCP
TEG B Foam, C02, DCP

Types of Portable Fire Protection System

ABC Dry chemical powder type fire extinguisher.

ABC Dry chemical powder type fire extinguishers provided in the complex are of
two capacities. These are 4kg and 9kg capacities.
These extinguishers are suitable for solid, liquid/ gas fires. They are also suitable
for fires in and outdoors electrical equipment & cable fires.
ABC Fire extinguisher are based on Mono-ammonium phosphate with nitrogen
expellent and are suitable for all fires.

Action of Extinguisher

Heat Absorption by sold particle

Interupts the chain reaction
The idea behind a dry chemical fire extinguisher is to blanket the fuel with an
inert solid (similar to dirt or sand).
A dry chemical extinguisher sprays a very fine powder of sodium bicarbonate
(NaHCO3, Baking Soda), Potassium bicarbonate(KHCO3, nearly identical to baking
soda) or monoammonium phosphate ((NH4)H2PO4) These solids coat the fuel and
smother the fire

Method of Operation.
Carry the extinguisher to the place of fire and keep it upright.
Remove the safety clip and strike the knob located in the cap to actuate
The piercing mechanism which in turn breaks the sealing disc of the cartridge.
Direct the stream of escaping powder at the base of the flame.
For effective result stand about 1.5 to 2.4 m away and direct the stream near the
seat of fire.
Progress forward,moving the nozzle rapidly with a side to side sweeping motion

When using on outdoor fires always operate the extinguisher from the upwind
side of the fire to extend the effective range of spray.
Minimum effective discharge time of 4Kg : 22 sec @ 5 m throw
Minimum effective discharge time of 9Kg : 20 sec @6 m throw
Hydrotest carried out on fire extinguisher body at test pressure of 45 bar at every
3 years

Carbon Dioxide type fire Extinguisher

Carbon dioxide type fire extinguisher of 4.5 kg & 22.5 kg capacity are provided at
RIL-BMD for electrical/electronic panels and equipment in process control room,
plant interface buildings, sub station and other facility having electrical/electronic
equipment.
The extinguisher consist of a high pressure seamless cylinder fitted with a high
pressure valve and a high pressure discharge hose with plastic horn. A plastic grip
is provided on discharge hose near the horn.

Action of Extinguisher
Carbon dioxide (CO2) is effective as an extinguishing agent primarily because it
reduces the oxygen content of air to a point where combustion cannot
continue/sustain i.e. by smoothering action. The cooling effect is limited unless
the object becomes coated with carbon dioxide. CO2 is non combustible and does
not react with most substances. Being a gas it can penetrate and spread to all
areas affected by fire.
When the extinguisher is actuated caron dioxide from the cylinder comes out at a
considerable velocity into the atmosphere and forms a layer of gas which is about
1.5 times heavier than air. The vapour blanket puts out the fire by displacing the
air around the fire and reducing the oxgen supply needed to continue
combustion.

Method of Operation

Carry the extinguisher to the place of fire

Remove the safety pin and operate the discharge device and unscrew he valve
depending upon the design.
Carbon dioxide is delivered by means of discharge horn through a high pressure
flexible hose.

Direct the jet at the base of the fire, starting at one edge and sweeping across the
surface of the burning material. When used in open air, the operator should stand
on the up wind side of the fire and should apply the gas in the down wind
direction as close as possible to the fire. On fires in electrical equipment first
switch off the current.Then direct the jet or horn straight at the fire.
The gas at the time of discharge makes considerable noise. The user should
therefore be well conversant with its operation to prevent the jet from being
misdirected during the few vital seconds.

Note: Carbon dioxide is filled inside the cylinder at a pressure of 52 kg/cm2

An operating instruction is pasted on the container, which shows the operation
and suitability of the extinguisher. The extinguisher is designed & fabricated and
bearing IS 2878 certification mark.

The extinguisher gives the following test result:

Hydrostatic test pressure : 250 kg/cm2
Performance test discharge duration: 10 to 24 sec

It is percentage by volume of the extinguishing media which is required to be

present in air to prevent combustion
CO2 is used for all type of fire, more effective in closed area

Limitations
a).Never use CO2 on metal fire and chemical having own supply of oxygen
b).Never remain in close area after application
AR-AFFF (Alcohol Resistance Aqueous Film forming foam)
(Used as portable monitors and fixed monitors)
 CONCLUSION

As one quoted “Fire is a good servant but a bad master”. Therefore in order to
prevent fire hazards in a complex chemical process plant the fire protection
system plays a very vital role in reducing the risk which are related not only to
fire hazards but other safety aspects of the plant.

My project on A case study on manufacturing process of Polyester fiber

involving ,Hazardou Chemicals & Fire Protection facilities at RIL(BMD)
focussed on the hazardous chemicals used in the process and the related fire
hazard associated with all the units of the plant and what are the facilities
available to over come these fire hazard arising from the various operations
of the plant. The project contains the information regarding the process of
manufacturing of polyester fiber and various hazardous chemicals used at the
site and all the fire protection facilities available at reliance industries limited
barabanki manufacturing division including fire hydrant sytems & its flow
rate testing according to NFPA291 , Fire water requirement /Demand, Foam
calculation /requirement (OISD,NFPA,TAC) at the site, types of portable fire
protection systems (Fire extinguishers) etc.

Hence these fire protection facilities at RIL-BMD exposed me to the practical

& analytical appraoch of the fire subject and helped me to utilize & corelate
my theoritical knowledge to practical knowlegde.
 REFERENCES

 Fire protection manual (TAC Rules)

 Oil Industries Safety Directorate 116
 National Fire Protection Association(NFPA)
 Factories Act 1948
 Jain, Virander K. Fire safety in buildings. Taylor & Francis, 2007